Bench PSU case for ATX power supply

This is a case designed to make use of an ‘old’ ATX PC power supply to make a bench power supply…

There are also some additional models for the PSU…
 

A carry handle > https://makerworld.com/en/models/742886


An accessories storage drawer > https://makerworld.com/en/models/1908605
 

DISCLAIMER! this is not a tutorial on how to build a bench PSU as there are many variants of ATX supply and component variation of parts I used… Please do your own research into the PSU you plan to use, how to wire everything and versions of the components used as there will no doubt be subtle differences…

Printing:
I used eSun PLA+ as I like its rigidity for practical projects like this… you can of course use whatever material you prefer..

For the ‘yellow’ I used eSun PLA+ Dark Yellow (marked as ‘Gold’ on the reel), for the black its eSun PLA+ HS in ‘black’ :)

You can of course go into the ‘objects’ and choose your own colour combos for the print

IMPORTANT!

Please note that due to its size (250mm tall) it will take up most of the build plate… the purge line at the back of the plate clears fine but the flow test lines WILL interfere… I haven't yet tried the print with flow calibration off as from memory this will still lay the outer most line which “should” clear the print area but tbh I just watch the printer and when its finished the flow calibration and returns the head to the back for the purge lines I just reach in and pull the flow calibration lines off the plate… 

The main case will use over half a reel of material (slicer suggests around 540g) and on its current profile settings will take 28hrs on my X1C… I have tried to minimise the amount of material used by designing out the need for support material and using a bare minimum of 2 perimeters with 15% gyroid infill to give the case a bit of rigidity and strength. You can of course do what you feel comfortable with

I have the front and rear panels set for a textured plate as this gives a nice finish to the parts and a smooth plate for the other parts

I used M3x5.7 inserts in the case to fix the front and rear panel onto the case. I used M3x8 button head bolts to fix the panels on
 

The feet use M4x12 bolts… pull the nuts into the case using the bolts… they are a little tight to push in but will pull in fine

The PSU support uses M3x14 bolts… the nuts again are a tight fit but will pull in…

I use some 20mm rubber stick on feet to finish up…

You will have to excuse the pictures of the testing as the camera was picking up all sorts of flickering but the displays are stable

The wiring looks like this…

…and connects to the PSU like this
 

Parts used for my build:

1 x ATX PSU… I had an old Corsair RM850i from my PC… this is 850w, 12v is up to 70a and 5v/3.3v up to 20a output… I have fused for 5a as this feels enough

1 x ZK-5KX DC Buck-Boost Converter (5A)… this takes 12v from the PSU and will boost it up to 36v variable across 0-36v
 

3 x DC 100v 10A dual digital displays (DSN-VC288 or equivalent)…

4 x 2 pin 2 position SPST round switches (6A 250v)

4 x 20mm panel mount fuse holders

1 x USB charger socket… mine was a Ktilura USB Car Charger Socket,12V 3 Port Fast Charging Outlet Panel, Dual 18W QC3.0 USB-A & 30W PD Type C Charger Power Outlet Panel with Switch LED (copied from the amazon description)
 

14 x M3x5.7 brass threaded inserts (heat/ultrasonic)
14 x M3x8 cap/button head bolts for panels
2 x M3x14 for PSU support
1 x 3mm LED for the power light
4 x 4mm banana speaker style posts